Seating cushion pad for a chair

ABSTRACT

A seat cushion pad is provided that includes a base with an array of coiled springs positioned on an upper surface of the base. A machine spun fiber foam layer rests on top of the array of coiled springs with a high-density foam sidewall surrounding the array of coiled springs and resting on the top surface of the base. An upper base layer made of high density foam rests on the sidewall with a pliable and elastic low density polyurethane foam layer pad on top of the upper base layer. A material cover encloses the high-density foam sidewall, the upper base layer, and the low density polyurethane foam layer pad.

FIELD OF THE INVENTION

The present invention relates to furniture, and in particular to a seating cushion pad for a chair.

BACKGROUND OF THE INVENTION

A chair is a piece of furniture with a raised surface supported by legs, commonly used to seat a single person. Chairs are supported most often by four legs and have a back. Chairs are made of a wide variety of materials, ranging from wood to metal to synthetic material (e.g., plastic), and chairs may be padded or upholstered in various colors and fabrics, either just on the seat (as with some dining room chairs) or on the entire chair.

Ergonomics and user comfort are a prime concern when a chair is designed. The padding in the seat and/or shape of the seat should provide the proper support to the user, as well as providing proper ventilation to avoid heat buildup when the user sits for an extended period of time. In addition, the cushion should be durable, and the cushion should retain its shape overtime.

Thus, there exists a need for improved seating designs that offer improved ergonomic support, user comfort, and durability.

SUMMARY OF THE INVENTION

A seat cushion pad is provided that includes a base with an array of coiled springs positioned on an upper surface of the base. A machine spun layer of fibers formed of thermoplastic elastomers provide a foam layer with air flow that rests on top of the array of coiled springs with a high-density foam sidewall surrounding the array of coiled springs and rests on the top surface of the base. An upper base layer made of high density foam rests on the sidewall with a pliable and elastic low density polyurethane foam layer pad on top of the upper base layer. A material cover encloses the high-density foam sidewall, the upper base layer, and the low density polyurethane foam layer pad.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further detailed with respect to the following FIGURES that depict various aspects of the present invention.

FIG. 1 is an exploded partial perspective view of an embodiment of the inventive seat pad with a material covering removed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention has utility as a chair cushion or seating pad. Embodiments of the inventive seating cushion pad provide improved ergonomic support and user comfort. A feeling of cloud comfort seating is felt by a person seated on embodiments of the inventive cushion or pad in response to a layer of machine spun fibers, formed of thermoplastic elastomers that provide a foam with channels that allow air flow, encapsulated in the cushion design. The machine spun thermoplastic elastomer fibers allow air flow through the foam that provides a source of ventilation to avoid heat buildup when the user sits for an extended period of time on the cushion. Thermoplastic elastomers are structurally strong and because this foam is spun of plastic based on thermoplastic elastomers the warranty on the material is much longer than that of polyurethane foam that breakdowns faster. The cells in polyurethane foam crush under the weight of a person's body, and it has been found that within six months to one-year cushions using polyurethane foam will not rebound well and become flat. This is not good for seat cushions.

In a specific inventive embodiment, the layer of machine spun fibers may be formed of thermoplastic polyester elastomer (TPEE). TPEE material is recyclable which is positive for the environment. Furthermore, TPEE requires less energy to be produced compared to other plastics. TPEE based fibers are also easy to work with and to be spun on a machine.

FIG. 1 is an exploded partial perspective view of an embodiment of the inventive seat cushion 10 with a covering removed. A base 12, which may be made of plywood or a composite material, serves as an attachment point for chair legs attached to the lower face of the base 12. In addition, a covering may be stapled or fixedly attached to the base 10. The covering may be a woven material made of natural or synthetic fibers, suede, leather, or a combination thereof. It is appreciated that solid coverings such as suede or leather may have a vent to allow for airflow into the cushion 10. An array of coiled springs 14, which may be hand tied, are positioned on the upper surface of the base 12. A machine spun fiber foam layer 16 provides air flow paths and rests on the top of the array of coiled springs 14. A spring of the array 14 in some inventive embodiments has a fabric sheath 15 associated with the circumference. The machine spun fiber foam layer 16 is formed as a mesh of foam strands of fiber. The array of coiled springs 14 and the machine spun fiber foam layer 16 are surrounded by a high-density foam sidewall 18 and capped with an upper base layer 20 of high density foam. The high-density foam may be formed from polyurethane polymers. A pliable and elastic low density polyurethane foam layer pad 22 rests on top of the upper base layer 20. A volume 24 containing the array of coiled springs 14 and the machine spun fiber layer 16 is in fluid communication with surrounding air external to cushion 10.

It is appreciated that the fibers used in the machine spun fiber layer 16 may be a sparse unwoven polymer such as cellulose, Nylon, or spun polypropylene fiber. The polymeric component of an inventive fiber is readily selected from any of the types of polymers known in the art that are capable of being formed into fibers, including polyolefins, polyvinyl, polyvinyl alcohol, polyesters, polyamides, co-polymers containing any of the aforementioned polymers as blocks of a copolymer, and combinations thereof. Specific polyolefins operative herein illustratively include polypropylene; polyethylene; polybutene; and polyisobutylene; polyamides such as NYLON 6 and NYLON 6,6; polyacrylates; polystyrenes; polyurethanes; acetal resins; polyethylene vinyl alcohol; polyesters such as polyethylene terephthalate (PET), polyethylene naphthalate, polytrimethylene terephthalate, poly(1,4-cyclohexylene dimethylene terephthalate) (PCT), polycarbonates; and aliphatic polyesters such as polylactic acid (PLA); polyphenylene sulfide; thermoplastic elastomers; polyacrylonitrile; cellulose and cellulose derivatives; polyaramids; acetals; fluoropolymers; copolymers and terpolymers thereof and mixtures or blends thereof, and without regard as whether a given polyolefin is syndiotacic, eutectic, isotactic, or atactic.

The foregoing description is illustrative of particular embodiments of the invention, but is not meant to be a limitation upon the practice thereof. The following claims, including all equivalents thereof, are intended to define the scope of the invention. 

1. A seating cushion pad comprising: a base; an array of coiled springs positioned on an upper surface of the base; a machine spun fiber foam layer that provides air flow channels rests on top of the array of coiled springs; a high-density foam sidewall surrounding the array of coiled springs and resting on the top surface of the base; an upper base layer made of high density foam resting on the sidewall; a pliable and elastic low density polyurethane foam layer pad that rests on top of the upper base layer; and a material cover that encloses the high-density foam sidewall, the upper base layer, and the low density polyurethane foam layer pad.
 2. The seating cushion pad of claim 1 wherein the base is made of plywood or a composite material, and the base is an attachment point for chair legs attached to a lower face of the base.
 3. The seating cushion pad of claim 1 wherein the coiled springs are hand tied.
 4. The seating cushion pad of claim 1 wherein the machine spun fiber foam layer is formed as a mesh of foam strands of fiber.
 5. The seating cushion pad of claim 1 wherein the fiber used in the machine spun fiber foam layer is a sparse unwoven polymer comprising cellulose, Nylon, or spun polypropylene fiber.
 6. The seating cushion pad of claim 1 wherein the fiber used in the machine spun fiber foam layer is formed of thermoplastic elastomers.
 7. The seating cushion pad of claim 1 wherein the fiber used in the machine spun fiber foam layer is formed of thermoplastic polyester elastomer (TPEE).
 8. The seating cushion pad of claim 1 wherein the high-density foam of the sidewall and upper base is formed from polyurethane polymers.
 9. The seating cushion pad of claim 1 wherein the covering is a woven material made of natural or synthetic fibers, suede, leather, or a combination thereof.
 10. The seating cushion pad of claim 9 wherein coverings made of suede or leather have a vent. 